Articles and methods for applying color on surfaces

ABSTRACT

Articles for applying color on a surface that includes a sheet of dry color component having a margin, a front sheet surface, and a rear sheet surface opposite the front sheet surface, and an adhesive on the rear sheet surface for bonding the sheet to the surface. Either the margin of the sheet or the entire sheet is adapted for reducing or eliminating the visual perceptibility of the seam created when the margin is positioned in an overlapping, abutting, or spaced apart relationship with a margin of a juxtaposed second article. The reduction or elimination of the visual perceptibility of the seam may be promoted by a physical mechanism, a chemical mechanism, an optical mechanism, or a combination of these mechanisms.

CROSS REFERENCE TO RELATED APPLICATION

This application claims the benefit of U.S. Provisional Application No.60/380,224, filed May 13, 2002 (P&G Case 8932P), and claims priority toU.S. application Ser. No. 10/324,237, filed Dec. 19, 2002 (P&G Case8817M) and claiming the benefit of U.S. Provisional Applications No.60/343,146 filed Dec. 20, 2001 (P&G Case 8817P), 60/380,225 filed May13, 2002 (P&G Case 8817P2), and 60/380,205 filed May 13, 2002 (P&G Case8817P3), and also claims priority to U.S. application Ser. No.10/324,559, filed Dec. 13, 2002 (P&G Case 8817M2) and claiming thebenefit of U.S. Provisional Applications No. 60/343,146 filed Dec. 20,2001 (P&G Case 8817P), 60/380,225 filed May 13, 2002 (P&G Case 8817P2),and 60/380,205 filed May 13, 2002 (P&G Case 8817P3).

FIELD OF THE INVENTION

The present invention relates to articles and methods for applying colorand, in particular, to articles and methods for applying a dry colorantto a surface.

BACKGROUND OF THE INVENTION

It is often desirable to apply one or more colors to a surface, forexample an architectural surface such as an interior or exterior wall orthe like, for aesthetic benefits and/or functional benefits such aswater resistance. Color is typically provided by conventional paintingwith water-based or oil-based wet paints, application of wallpaper orthe like. The laborious processes involved with wet painting and wallpapering are well known. Typically, it is necessary to protectsurrounding areas from collateral mess during such activities by tapingadjacent surfaces where the color is not desired, arranging drop clothesto protect floors and furniture, and the like. Extreme care must also beexercised to avoid dripping of paint, wallpaper paste or primer, orother wet-applied materials. Many wet paint and wall paper products arealso recommended for use together with one or more primers or bases toassist in coverage and/or durability of the desired color, therebyincreasing the time and labor for producing a desired color effect onsuch a surface.

Additionally, it is typically necessary to saturate brushes, rollers orother applicators with paint, primer, paste or the like in order toapply the material to a surface. As a result, a significant amount ofmaterial is wasted, as it never reaches the intended surface, butremains on the applicator. Cleaning of brushes, sprayers, rollers andother tools used in application of wet paint and wall paper oncepainting or wall papering is completed, or at least suspended for aperiod of time, such as overnight, is also time consuming.

Many paints adapted for application to surfaces such as architecturalsurfaces include one or more volatile organic compounds. Such paintsrelease noxious fumes during and after application, thereby requiringventilation during and after application, particularly in closedenvironments such as buildings.

In structural surface covering operations that incorporate multiplestrips or sheets of material, a seam is formed between each juxtaposedpair of strips. Seams provide imperfections that detract from theaesthetic appearance, or some other property, of the facade presented bythe strips. Consequently, seam concealment is a significant concern insuch structural surface covering operations. For example, the seamsbetween adjacent dry wall panels are covered with drywall tape. Withregard to covering operations that apply color to a surface, wallpaperis applied to interior walls by pasting multiple strips adjacent to eachother. Wallpaper may be systematically applied to an interior wall byaligning a vertical edge of an initial strip with a plumb line drawn onthe wall. At least one of the opposite vertical edges of the initialstrip operates as a verticality guide for the application of subsequentstrips of wallpaper. Adjacent ones of the strips are positioned inabutment so as to minimize the presence of gaps between juxtaposedmargins or the occurrence of overlap. Typically, however, the verticalseams between adjacent pairs of strips are visibly perceptible. Thevisual presence of the vertical seams detracts from the aestheticappearance of the color applied to the surface by the wallpaper.

Thus, in spite of the obvious aesthetic and/or functional benefitsprovided by applying color on a surface by conventional techniques suchas wet painting or wall papering, the efforts required in connectionwith such procedures are inconvenient and time consuming and, moreover,the color applied to the surface may incorporate one or more seams thatdetract from the manifestation of the color effect to an observer.

SUMMARY OF THE INVENTION

The present invention is directed to an article for applying color on asurface that includes a sheet of dry colorant having a peripheral edge,a margin adjacent to the peripheral edge, a front sheet surface, a rearsheet surface opposite the front sheet surface, and an adhesive on therear surface for bonding the sheet to the surface. The sheet has athickness of less than 3.0 mils. In various embodiments of theinvention, the margin of the sheet, or the entire sheet including themargin, is adapted to reduce the visual perceptibility of a seam createdwhen two sheets are positioned with a juxtaposed relationship.

BRIEF DESCRIPTION OF THE DRAWINGS

Various advantages, objectives, and features of the invention willbecome more readily apparent to those of ordinary skill in the art uponreview of the following detailed description of the preferredembodiments, taken in conjunction with the accompanying drawings.

FIG. 1 is a diagrammatic top view of an article for applying color to asurface according to the present invention;

FIG. 2 is a diagrammatic end view of the article of FIG. 1;

FIG. 3 is a diagrammatic end view of two articles, as in FIG. 1, appliedwith a juxtaposed relationship to the surface such that a gap is formedbetween the articles;

FIG. 4 is a transverse cross-end view of a filler strip constructedaccording to the principles of the present invention for filling a gapbetween adjacent articles as illustrated in FIG. 1;

FIG. 5 is a diagrammatic end view of a juxtaposed pair of articleshaving overlapping margins;

FIG. 6 is a diagrammatic end view similar to FIG. 5;

FIG. 7 is a diagrammatic end view of an article in which the margins arethinned according to principles of the present invention;

FIG. 8 is a diagrammatic end view of an article in which the margins arethinned according to principles of the present invention;

FIGS. 9A and 9B are diagrammatic cross-sectional views of an article inwhich the margins are thinned according to principles of the presentinvention;

FIG. 10 is a diagrammatic cross-sectional view of a portion of anarticle having microparticles according to principles of the presentinvention;

FIG. 11 is a diagrammatic end view of a portion of an article havingprojections according to principles of the present invention;

FIG. 12 is a diagrammatic cross-sectional view of a portion of anarticle having a cellular structure according to principles of thepresent invention;

FIG. 13 is a diagrammatic view of a portion of an article havingcontoured peripheral edges according to principles of the presentinvention;

FIG. 14 is a diagrammatic view of a portion of an article having apattern according to the principles of the present invention;

FIG. 15 is a diagrammatic cross-sectional view of a portion of anarticle having a three-dimensional topography according to theprinciples of the present invention; and

FIG. 16 is a schematic diagram of one process for producing an articlefor applying color on a surface according to the principles of thepresent invention.

DETAILED DESCRIPTION

The present invention is directed to articles and methods for applyingcolor on a surface. As employed herein, the term “color” is used torefer to a color effect, i.e., a difference in color or visualperception. In a specific embodiment, the color effect is asubstantially permanent color effect, i.e., a color effect which is notremoved upon casual contact, light washing, or the like. Thus, asubstantially permanent color effect is distinguished from a temporarycolor effect which can be easily removed or reduced, such as thatprovided by chalk or crayons. The terms “colorant” and “color component”are used synonymously herein to refer to the component of the inventivearticles, which provides the color effect. Specifically, the colorant isany composition that provides opacity coverage to a surface to which itis applied and, generally, the colorant comprises a dry pigment or dye,alone or in combination with additional components. For example, thecolorant may be a dry paint including pigment particles, otherconventional paint components, and a liquid carrier that has beensubstantially removed by vaporization during the process to providingthe dry paint.

As another example, the colorant may be an engineered sheet or laminateformed from suitable thermoplastic resins and including a substance,such as pigment particles or dye molecules, in a sufficientconcentration and with an appropriate distribution to produce a coloreffect. Specifically, the colorant may be formed from thermo-formableengineering polymer resins, including but not limited to acrylics,urethanes, polyvinyl chloride (PVC), polyvinylidene fluoride (PVDF) andpolyvinylidene chloride (PVDC). The various layers of the colorant maypossess differing compositions and/or properties effective to applycolor to a surface.

The term “surface” is used herein to refer to any outer layer orboundary of an object or substrate which is capable of receiving a colorcomponent thereon. Suitable surfaces may be substantiallytwo-dimensional and flat or substantially three-dimensional andincluding curves, angled portions or the like. In one embodiment, thesurface to which color component is applied using the articles andmethods of the invention comprises an architectural surface, i.e., asurface of a building, a building fixture (i.e., appliances), furniture,and the like. The architectural building surface may be an interiorsurface within the building or an exterior surface on an outer portionof the building. Substantially three-dimensional architectural surfacescan include, for example, edge treatments of two-dimensional surfacessuch as moldings (e.g., moldings around windows or doorways),floorboards, appliances, furniture, and the like. The architecturalsurface may be permanently installed or may be temporarily installed orportable. The products of the present invention can further be appliedto surfaces of articles to give them the same or different textureand/or appearance of architectural surfaces. For example, the productshereof can be used to apply a color layer to appliances, furniture, andother architectural articles. Additional surfaces suitable forapplication of color using the articles and methods of the presentinvention will be apparent to those skilled in the art in view of thepresent disclosure.

With reference to FIGS. 1 and 2, an article 10 for applying color on asurface (not shown) according to the present invention includes a planarsheet 12 of a dry colorant or dry color component and a layer 25 of anadhesive or bonding agent. The sheet 12 has a front sheet surface 14, arear sheet surface 16 opposite the front sheet surface 14, fourperipheral edges 20, 22, 24, 26, and a margin 18 disposed adjacent toperipheral edges 20, 22, 24, 26. The margin 18 defines an annular stripor band of dry colorant extending circumferentially about the peripheraledges 20, 22, 24, 26 of the sheet 12 and inwardly a given dimension orwidth toward the center of the sheet 12. Examples of articles 10 aredisclosed in U.S. Provisional Application No. 60/343,146, entitled“Articles and Methods for Applying Color on Surfaces” and filed on Dec.20, 2001, U.S. Provisional Application No. 60/380,225, entitled“Articles and Methods for Applying Color on Surfaces” and filed on May13, 2002, and U.S. Provisional Application No. 60/380,205, entitled“Articles and Methods for Applying Color on Surfaces” and filed on May13, 2002. Each of these applications is hereby incorporated by referenceherein in its entirety. The article 10 may be a laminate formed frommultiple layers of thermoplastic resins, as indicated by referencenumeral 19 and shown in dot-dashed lines in FIG. 2.

Typically, the sheet of dry color component will have a thickness ofless than about 0.003 inch (3 mils or 0.08 mm). In one embodiment, thesheet of dry color component will have a thickness of from about 0.0003inch (0.3 mils) to about 0.003 inch (about 0.008 mm to about 0.08 mm),more specifically from about 0.0003 inch to about 0.0015 inch (about0.008 mm to about 0.04 mm). In another embodiment, the sheet of drycolor component will have a thickness about 0.0007 inch (0.02 mm) orless, and even more specifically not more than about 0.0005 inch (0.013mm).

In embodiments wherein the article comprises the sheet of dry colorcomponent and adhesive, in the absence of layers such as liners orcarriers, the thickness of the articles will be essentially that of thesheet of dry color component, as the adhesive layer is typicallyrelatively thin, i.e., generally less than about 1 mil (0.001 inch or0.03 mm) in thickness, more specifically about 0.5 mil (0.0005 inch or0.013 mm) in thickness. Thus, in one embodiment, the sheet of dry colorcomponent and adhesive combined have a thickness of about 0.003 inch (3mils or 0.08 mm) or less, more specifically from about 0.0003 inch toabout 0.003 inch (about 0.008 mm to about 0.08 mm), even morespecifically from about 0.0003 to about 0.0015 inch (about 0.008 mm toabout 0.04 mm), and yet more specifically about 0.0007 inch (0.013 mm)or less. Advantageously, edges of adjacent sheets may thus be overlappedwithout significant overlap appearance. In further embodiments whereinone or more releasable liners are included, the thickness of thearticles will be increased.

The adhesive layer 25 is applied to a substantial portion of the rearsheet surface 16 of sheet 12. The adhesive layer 25 may be any bondingagent operative for creating a secure adhesive bond between the article10 and a surface (not shown). A particularly suitable adhesive ispressure-sensitive so that the article 10 can be secured to the surfaceand repositioned before applying a pressure of a magnitude sufficient tocreate a final adhesive bond with the surface.

The article 10 may be wound into a roll and applied to the surface witha suitable applicator (not shown) operative for dispensing the article10 in a controlled manner. Alternatively, the article 10 may be appliedto the surface manually without the use of an applicator. It isappreciated that the applicator may facilitate, or otherwise implement,certain embodiments of the present invention for eliminating, reducing,or otherwise lessening the visual perceptibility of seams between anadjacent pair of articles 10.

Because the dimensions of the article 10 are limited, multiple articles10 are positioned with an adjoining or juxtaposed relationship to applycolor to certain surfaces, such as architectural surfaces includinginterior and exterior walls of residential and commercial buildings. Asa result, one of the peripheral edges 20, 22, 24, 26 of one sheet 12 ispositioned adjacent to one of the peripheral edges 20, 22, 24, 26 ofanother adjacent sheet 12. Depending upon the precise placement of thesheets 12, the respective margins 18 of the juxtaposed pair of sheets 12are overlapping, abutting, or separated or spaced apart by a groove orgap so as to create a seam. The seam presents an irregularity in theotherwise smooth, uninterrupted coverage of the surface by the articles.

Seams tend to be visually perceived or discerned by an observer and, ifuncorrected, degrade the aesthetic appearance of color supplied by thearticles 10 to the surface. According to the principles of the presentinvention, the visual perceptibility of the seam may be lessened,reduced or eliminated by modifying one or more properties orcharacteristics of article 10. The change in visual perceptibility ofthe seam may be promoted by a physical mechanism, a chemical mechanism,an optical mechanism, or combinations thereof.

Adjacent articles 10 may be overlapped or gapped due to, for example,imprecision during application to the surface. Overlaps or gaps betweenadjacent articles 10 may also be introduced due to dimensionalirregularities in the surface to which the articles 10 are beingapplied. For example, architectural surfaces can bow in and out, sway,lean and frequently lack plumb inner and outer corners. Furthermore,features such as windows and doors present in most architecturalsurfaces are often out of vertical plumb, sometimes dramatically, andthe ceiling line can sway and dip unevenly. These irregularities can beproduced by settling of the structural components of the building or byconstruction errors. Overlap is also present when a custom dimensionedarticle is used to patch an existing color effect on a surface to, forexample, cover or conceal a mark or to cover a small area from which theoriginal color has been removed.

With reference to FIG. 3 in which certain dimensions are exaggerated forpurposes of illustration, a plurality of, for example, two articles 10may be applied to a surface 28 so as to create a gap or groove 30between each juxtaposed pair of articles 10. The adhesive layer 25 ofeach article 10 contacts a confronting portion of the surface 28 andpromotes an adhesive bond therebetween. When the articles 10 are appliedto the surface 28, margin 18 of one sheet 12 is juxtaposed in anon-overlapping manner with margin 18 of the adjacent sheet 12 so as togenerate the groove 30. The groove 30 may have uniform width or avarying width and may be linear or non-linear along extent of thejuxtaposition.

According to principles of the invention, a filler may be introducedinto the groove 30 after the articles 10 are applied to surface 28. Thefiller may have any suitable structure or form having one or morecharacteristics capable of reducing the visual perceptibility of thegroove 30.

In one embodiment, the filler is a grout 31 composed of a spreadablematerial that has physical attributes at ambient temperature, such as asuitably low-viscosity to promote spreadability, suitable for beingreceived into the groove 30. The grout 31, after application and curing,may be any material having visual characteristics similar to the visualcharacteristics of the sheet 12 of the adjacent articles 10 and,preferably, any material that is imperceptible or indistinguishable invisual appearance with the visual appearance of sheet 12 of the adjacentarticles 10. To that end, the grout 31 may incorporate a polymer orresin similar to the polymer or resin forming the base material of thesheet 12 or the base material of at least one layer of the sheet 12 thatis laminated. The grout 31 typically incorporates a substance, such as apigment or a dye, operative to provide the desired visualcharacteristics and a suitable solvent or other spreading agent. Afterthe grout 31 is received in the groove 30, a portion of the spreadingagent preferably evaporates over a characteristic curing time duringwhich, among other things, the viscosity of the grout 31 issignificantly reduced.

The present invention contemplates that the grout 31 may be applied tothe groove 30 between juxtaposed articles 10 either manually or with theassistance of an applicator (not shown). Specifically, for manualapplication, grout 31 is introduced or injected into groove 30 and wipedor troweled to remove any excess so that the residual grout 31 isgenerally co-planar with the respective front sheet surfaces 14 ofsheets 12. An applicator suitable for use in this aspect of the presentinvention includes a reservoir, which may be refillable, holding aquantity of the grout 31, a dispensing element for introducing the grout31 at a regulated uniform rate into the groove 30, and a troweling orwiping element for removing any excess grout 31 not received in thegroove 30.

In another embodiment of the invention and with reference to FIG. 4,another suitable filler according to the present invention is a fillerstrip 32 having any form capable of being associated with the groove 30in a manner that eliminates, reduces, or lessens the visualperceptibility of groove 30. As illustrated, the filler strip 32includes a center portion 34 and opposed thinner, flexible marginalportions 36, 38 flanking the center portion 34. The center portion 34 isadapted to be at least partially received into the groove 30 with eachof the marginal portions 36, 38 overlapping a corresponding one of themargins 18 of the two sheets 12. In one embodiment, the center portion34 is rigid and the marginal portions 36, 38 are malleable orconformable. Preferably, the filler strip 32 substantially fills thegroove 30 in a manner that resists substantial removal forces afterapplication. As illustrated, the thickness of the marginal portions 36,38 is less than a thickness of each sheet 12 so that the marginalportions 36, 38 add a minimal incremental thickness to the overallthickness of the adjacent articles 10. Alternatively, the marginalportions 36, 38 of the filler strip 32 may be optically transparent ortranslucent such that the color provided by sheets 12 is visibletherethrough.

With reference to FIGS. 5 and 6 in which certain dimensions areexaggerated for purposes of description, multiple articles 10 may beapplied for delivering a color to a surface such that the margin 18adjacent one of the peripheral edges 20, 22, 24, 26 of one sheet 12 hasan overlapping relationship with the margin 18 adjacent one of theperipheral edges 20, 22, 24, 26 of another sheet 12. As illustrated inFIGS. 5 and 6, a portion of the margin 18 of the overlying sheet 12provides an overseam 44 with an exposed surface visible to an observerand a portion of the margin 18 of the underlying sheet 12 is captured asan underseam 46 between the overseam 44 and the surface 28. Typically,the overlap between overseam 44 and underseam 46 will be less than orequal to about 0.5 inches, although the present invention is not solimited as it is contemplated that the overlap between the articles 10could extend over the entire area of sheet 12. The average thickness ofthe overlapping overseam 44 and underseam 46 is less than about 6 mils.Collectively, the overseam 44 and underseam 46 form a seam that, if notmodified according to one or more embodiments of the present invention,would otherwise likely be visually perceived by an observer of the coloreffect provided to the surface 28.

With continued reference to FIGS. 5 and 6, the overseam 44 and underseam46 may be characterized in three dimensions by a height in az-direction, a width in the x-direction, and a length in they-direction. It is appreciated that the seam, formed by overseam 44 andunderseam 46, extends in the y-direction into the plane of the page ofFIGS. 5, 6 and that the effective dimension of the seam in thex-direction typically varies in the y-direction. The incremental heightadded by the overseam 44 in the z-direction is substantially equal tothe thickness of margin 18. A portion of the seam may have anon-contacting relationship with the surface 28 so that a cavity 48 iscreated between a portion of the margin 18 and the surface 28. Anotherportion of the overseam 44 creates an abrupt, sharp edge at peripheraledge 24. The discontinuity in the otherwise substantially planar surfaceof the juxtaposed articles 10 introduced by the presence of edge 24provides an observable or perceptible visual indication of the locationof edge 24 to a viewer of surface 28.

According to the principles of the present invention, the entire sheet12 or at least the margin 18 of sheet 12 near at least one of theperipheral edges 20, 22, 24, 26 is modified in a manner that eliminates,reduces or lessens the visual perceptibility of the overseam 44 createdby the overlap between the respective margins 18 of a juxtaposed pair ofsheets 12. It is contemplated that the various principles of the presentinvention may be combined for achieving the elimination, reduction orlessening of the visual perceptibility of the seam provided by theoverlapping overseam 44 and underseam 46.

In one embodiment of the present invention, the margin 18 adjacent atleast one of the peripheral edges 20, 22, 24, 26 is thinner, beforeapplication to surface 28, than other portions of sheet 12 laterallydisposed between the margins 18. Typically, the average thickness of themargin 18 adjacent at least one of the peripheral edges 20, 22, 24, 26may be reduced to about one-half of the thickness of the remainingportions of the dry colorant sheet so that, after overlapping, thecomposite thickness of the sheets is uniform or substantially uniform.However, the present invention is not so limited. All regions of thearticle 10, including the overlapping overseam 44 and underseam 46 whenthe margin 18 is overlapped with the margin 18 of another sheet 12,should have an opacity index ranging from about 0.95 to 1.0, as measuredaccording to ASTM D2805 entitled “Standard Test Method for Hiding Powerof Paints by Reflectometry (Spectrometer).”

Referring to FIG. 7 and according to one specific embodiment of thepresent invention in which the margin is thinned, the margin 18 of sheet12 is beveled or tapered outwardly toward peripheral edges 20, 24. It isappreciated that the margin may be tapered adjacent to any of theperipheral edges 20, 22, 24, 26. As illustrated in FIG. 7, the margin 18is tapered toward the front sheet surface 14 toward peripheral edge 20and tapered toward the rear sheet surface 16 adjacent peripheral edge24. The tapering of margin 18 provides oppositely oriented wedge-shapedsurfaces 40, 42 that extend into and out of the plane of the page ofFIG. 7.

Specifically, margin 18 tapers from a first thickness at each ofrespective common boundaries 41, 43 shared with a peripherally inwardportion of the sheet 12 to a second lesser thickness at the respectiveperipheral edges 20, 24. As a result, the thickness of the margin 18decreases in a direction from each of the common boundaries 41, 43 tothe corresponding one of the peripheral edges 20, 24. It is appreciatedthat the margin 18 may be tapered with a non-uniform taper angle so thatthe thickness of the wedge-shaped surfaces 40, 42 is not monotonicallyvarying as illustrated in FIG. 7. For example, the margin 18 near atleast one of the peripheral edges 20, 22, 24, 26 may be feathered sothat the thickness in the z-direction and lateral width in thex-direction of the thinning vary randomly with location.

In another specific embodiment in which the margin is thinned and withreference to FIG. 8, the margin 18 of sheet 12 is shaped as a joint half45 at peripheral edge 20 and as a complementary joint half 47 at theopposite peripheral edge 24. When the margin 18 of one article 10 isoverlapped with the margin 18 of another article 10 and adhesivelysecured, the joint halves 45, 47 provide a complete lap joint. Theoverlapping lap joints 45, 47 preferably have an effective thicknessthat produces a flush or continuous surface with the peripherally inwardportions of each of the juxtaposed articles 10. It is appreciated thatjoint halves 45, 47 may have any complementary structure capable ofbeing associated as a lap joint and is not limited to the specificembodiment depicted in FIG. 8. With reference to FIGS. 7 and 8, anaverage thickness of the margin 18 illustrated in FIGS. 7 and 8 is lessthan an average thickness of peripherally-inward portions of sheet 12.It is contemplated by the invention that the margin 18 may be thinnedby, for example, providing wedge-shaped surfaces 40, 42 or joint halves45, 47, during manufacture of the article 10 by the forming process(e.g., printing of the sheet 12) or by a mechanical or wet chemicalprocess, after forming, that selectively removes a suitable thickness ofthe sheet 12. Alternatively, it is appreciated that mechanical and wetchemical thinning of the margin 18 may be performed at the point ofapplication of article 10 to the surface. Mechanical thinning processesgenerally rely on mechanical action, such as abrasion or cutting, formaterial removal whereas wet chemical thinning processes generally relyon a chemical reaction that etches, dissolves or otherwise removesmaterial. For chemical thinning, the thickness of removed material maybe controlled, for example, by regulating the exposure time of the drycolorant of the margin 18 to the etchant chemical. To that end, theetchant chemical may be applied with a suitable applicator and removedwith a device, such as a wet vacuum, or by simple wiping with anappropriate absorbent article or other removal device when the exposuretime lapses. It is contemplated that the etchant chemical may beprovided to the consumer in a kit also containing the article 10 forapplying color and that the applicator for the etchant chemical and/orthe removal device may be incorporated into the applicator for applyingthe articles 10 to the surface 28 (FIG. 5).

With reference to FIG. 9A and in accordance with the principles of thepresent invention, the sheet 12 of article 10 is formed from a pluralityof, for example, five layers 50-54 and is effectively thinned invicinity of the margin 18 by contouring at least the respectiveperipheral edges 20, 24 so as to provide a tiered or rounded edgestructure. To that end, the center layer 52 of sheet 12 projects in alaterally outward direction beyond layers 50, 51, 53 and 54 and layers51 and 53 project laterally outward beyond layers 50 and 54. When ajuxtaposed pair of the articles 10 is applied to surface 28 (FIG. 5)with margin 18 at, for example, peripheral edge 20 of one of thearticles 10 overlapped with, for example, peripheral edge 24 of anotherof the articles 10, the overlapping thickness of the overseam 44 andunderseam 46 will be significantly reduced due to the contact betweenthe respective rounded edge structures. In addition, the tiering of themargin 18 at edges 20, 24, when viewed at a typical viewing distancefrom surface 28, provides a rounded appearance that operates to furthereliminate, reduce or otherwise lessen the visual perceptibility of edges20, 24.

In an alternative embodiment and with reference to FIG. 9B, the sheet 12of article 10 is formed from a plurality of, for example, four layers55-58 and is rounded in vicinity of the margin 18 by contouring at leastthe respective peripheral edges 20, 24 so as to provide a tiered orrounded edge structure. Specifically, the laterally outward projectionof layers 55-58 progressively decreases from layer 55 to layer 58 sothat layer 55 projects outwardly the least relative distance and layer58 projects outwardly the greatest relative distance. Similar to theembodiment of the present invention illustrated in FIG. 9A, when a pairof the articles 10 are applied to surface 28 (FIG. 5) an edge 20 of oneof the articles 10 overlapped with another edge 24 of another of thearticles 10, the overlapping thickness will be significantly reduced. Inaddition, the tiering of edges 20, 24, when viewed by an observer at atypical viewing distance from surface 28, provides a rounded appearancethat operates to further eliminate, reduce or otherwise lessen thevisual perceptibility of edges 20, 24.

When margin 18 having one of the constructions illustrated in FIGS. 7,8, 9A and 9B is overlapped with a margin 18 of another juxtaposedarticle 10, which may have a complementary reduced-thicknessconstruction, the average opacity index of the entire surface of thearticle 10 is between about 0.95 and 1.0, as measured according to ASTMD2805. The average thickness of the overlapping portions of therespective margins 18 of a juxtaposed pair of articles 10 is less than 6mils.

According to another embodiment of the present invention and withrenewed reference to FIGS. 1 and 2, the visual perceptibility ofoverlapped margins 18 of adjacent articles 10 is eliminated, reduced orotherwise lessened by incorporating an additive operative to modify therheology of the sheet 12. The rheology-modifying additive is operativeto promote selective coalescence, densification or fusion of theoverlapped portions of the margin 18 of juxtaposed sheets 12. The actionof the rheology-modifying additive may occur spontaneously or with theassistance of an initiator. A compressive pressure may also be appliedto margin 18 at the point of application without departing from thespirit and scope of the invention. The rheology-modifying additive maybe any chemical agent that temporarily increases the workability andflexibility of the sheet 12. The rheology-modifying additive should beinactive, or otherwise dormant, while the article 10 is stored andbefore application to the surface 28 (FIG. 5). The rheology-modifyingadditive may volatize or evaporate from the margin 18, after acharacteristic working period, or may remain resident in the article 10after the coalescence is concluded. Once coalescence is concluded, therheology-modifying additive should be no longer present or should remainpresent in a concentration such that the article 10 is not overlysusceptible to mechanical damage.

It is appreciated that the rheology-modifying additive may be dispersedthroughout the dry colorant forming sheet 12 or may be locally confinedto dry colorant forming the margin 18. In either instance, theapplication of compressive pressure, if required to provide thecoalescence, can be restricted to the margin 18 by using a suitableroller of the like of a limited width. It is further appreciated thearticle 10 may need to be stored in a controlled environment aftermanufacture so as preserve the chemical action of rheology-modifyingadditives that are volatile. For example, articles 10 containing suchvolatile rheology-modifying additives may be stored after manufacture ina sealed container (not shown), such as a Mylar bag. The fluidimpermeable walls of such sealed containers would prevent or otherwiseinhibit loss due to volatilization, evaporation or vaporization of therheology-modifying additives until the article 10 is unsealed from thecontainer at the point of application for providing color to the surface28 (FIG. 5). It is appreciated that any loss of the rheology-modifyingadditive due to volatilization is significantly reduced if the article10 is merely tightly rolled.

In certain embodiments of the invention, the rheology-modifying additivemay be a plasticizer added to the formulation of the material formingthe sheet. The plasticizer would allow the dry colorant of the sheet 12to flow for a period until the concentration of temporary plasticizer issufficiently reduced by volatilization. Typically, the plasticizer willbe present in the dry colorant of sheet 12 after manufacture at aconcentration of less than about 30 wt. %. Plasticizers suitable for usein the present invention include propylene glycol, ethylene glycol,dibutyl phthalate and tricyresyl phosphate. Another plasticizer suitablefor use in the invention is benzyl phthalate, which is availablecommercially under the SANTICIZER® tradename from Ferro Corporation(Cleveland, Ohio). In addition, the rheology of thermoplastic polymersused to form article 10 may be modified by, for example, varying thetype of polymer resin, blending various different polymer resins, orvarying the molecular weight of the polymer.

In other embodiments of the invention and with continued reference toFIGS. 1 and 2, the rheology-modifying additive is a liquid-sensitivechemical agent operative to coalesce the margin 18, when selectivelyexposed to a suitable initiator consisting of an activation liquid atthe point of application, after the article 10 is applied to the surface28 (FIG. 5). The activation liquid promotes a chemical reaction with theliquid-sensitive chemical agent that coalesces the dry colorant formingthe margin 18 so that the thickness of the overlapped overseam 44 andunderseam 46 (FIG. 5) is reduced and so that the exposed edge 24 of theoverseam 44 is rounded or curved. Both effects are believed to reducingthe visual perceptibility of the overlapping ones of margins 18 of ajuxtaposed pair of articles 10.

The chemical reaction between liquid-sensitive chemical agent and theactivation liquid is controlled to provide a predetermined thicknessreduction of the overseam 44 and underseam 46 and/or rounding of theexposed edge of the overseam 44 (FIG. 5). Preferably, after apredetermined reduction and/or rounding is achieved, the activationliquid is consumed or spent and the chemical reaction ceases orotherwise halts. Alternatively, the activation liquid may be removed ora sufficient amount of an appropriate neutralizing agent may be added.The liquid-sensitive chemical agent and the activation liquid should becompatible with the chemistry of the dry colorant forming the sheet 12such that the physical properties and color of the article 10 are notsignificantly affected once coalescence is induced and concluded. Theliquid may be applied to sheet 12 at ambient temperature or heatedbefore application. It is appreciated that the liquid-sensitive chemicalagent may be dispersed throughout the dry colorant forming sheet 12 ormay be localized in the dry colorant forming the margin 18. If theentire sheet 12 contains the liquid-sensitive chemical agent, theapplication of the activation liquid should be controlled to wet onlythe margin 18, such as by employing a suitable applicator of arestricted effective application width. It is contemplated that theactivation liquid may be provided in a kit also containing the article10 for applying color and that the applicator for the activation liquidmay be incorporated into the applicator for applying the article 10 tothe surface 28 (FIG. 5).

In other embodiments of the invention and with continued reference toFIGS. 1 and 2, the rheology-modifying additive is a thermally-activatedchemical agent activated, at the point of application to surface 28(FIG. 5), when heated above ambient temperature. The thermally-activatedchemical agent has a characteristic activation temperature that must beexceeded to initiate the coalescence. Below the activation temperature,the thermally-activated chemical agent is substantially inactive orinactive. The activation temperature of the thermally-activated chemicalagent is selected such that article 10 does not experience anysignificant physical degradation or color change when heated to theactivation temperature. Such thermally-activated chemical agents causethe dry colorant of the overlapped overseam 44 and underseam 46 tobecome more densely packed or to level by spreading for reducing thecomposite thickness and rounding the exposed peripheral edge 24 of theoverseam 44 (FIG. 5).

To initiate coalescence, the margin 18 is exposed to a suitable heatsource, such as a flow of heated air from a blower, a heated applicatoror roller, or a laser, for a duration and at a temperature sufficient tocause the desired thickness reduction of the overlapped overseam 44 andunderseam 46 and/or rounding of peripheral edge 24 of overseam 44 (FIG.5). Optionally, a compressive pressure may be applied to margin 18 toassist the action of the thermally-activated chemical agent. If theentire sheet 12 contains thermally-activated chemical agent, theapplication of heat may be controlled so that only the margin 18 isheated to the characteristic activation temperature. For example, aheated roller of a suitable effective rolling width may be utilized.However, it is appreciated that the heat source may be operative totransfer heat by convection, conduction, radiation, or any combinationthereof.

The chemistry of the thermally-activated chemical agent should becompatible with the chemistry of the dry colorant such that the physicalproperties of the dry colorant are not significantly affected by thepresence of the thermally-activated compound, unless heat activated.Exemplary thermally-activated chemical agents appropriate for use in theinvention as a copolymer include ethylene-vinyl acetate copolymer andpolyvinyl acetate copolymer. Suitable ethylene-vinyl acetate resins areavailable under the tradename Ultrathen from Equistar (Houston, Tex.).Suitable polyvinyl acetate resins are available under the tradenameVINNAPAS® from Wacker Polymer Systems (Adrian, Mich.). Generally,ethylene-vinyl acetate copolymer and polyvinyl acetate copolymer areknown to have a softening range between about 50° C. and about 125° C.It is contemplated that other suitable copolymers could be selected thatwould have differing softening ranges for heat activation depending uponthe specific application.

Sheets 12 formed of engineered films containing thermoplastic resins arereadily deformed or placed in a state suitable for deformation by theapplication of a compressive pressure, when heated to a sufficientlyhigh temperature. It follows that the rheology-modifying additive may beintrinsic to the formulation of the thermoplastic resin. For example,the base thermoplastic resin of the sheet 12 may be blended with anotherthermoplastic resin to provide the requisite heat sensitivity forinducing coalescence.

It is appreciated that the rheology-modifying additive may be enclosedin microcapsules for release and activation upon the application of anexternal trigger. Any suitable method of microencapsulation may be usedto divide the rheology-modifying additive into minute liquid particlesand to surround particles of the rheology-modifying additive withrupturable enveloping walls formed of a material having a suitablecomposition. The material forming the enveloping walls should besufficiently thick and/or of a suitably compatible material to resistchemical attack by the encapsulated rheology-modifying additive and,preferably, is inert to the chemical action of the encapsulatedrheology-modifying additive. At the least, the material of theenveloping walls should be impermeable to the confinedrheology-modifying additive for a sufficient shelf life aftermanufacture to permit the articles 10 to be applied to the surface andrelease of the rheology-modifying additive. The microencapsulatedparticles of rheology-modifying additive may be evenly distributed witha uniform density in the sheets 12 or may be localized in the margin 18.

One method of initiating the action of the microencapsulated chemicalagent is to provide frangible enveloping walls sufficiently thin torupture upon mechanical or physical manipulation, such as a compressivepressure, during or shortly after application of the article 10 tosurface 28. The enveloping walls should have a thickness sufficient toprevent premature release of the chemical agent by accidental ruptureunder the physical manipulation occurring during mixing and sheetfabrication and during storage. Other initiation or activation triggersinclude, but are not limited to, release by dissolving the envelopingwalls with a suitable solvent and release by selectively exposing theenveloping walls to radiant energy such as heat or light.

In another embodiment of the invention and with continued reference toFIGS. 1 and 2, the rheology-modifying additive is a solvent at the pointof application and operative to coalesce the dry colorant of margin 18.Such solvents promote a chemical reaction with the dry colorant formingthe margin 18 that coalesces the polymer or resin base material of thedry colorant so that the thickness of the overlapped overseam 44 andunderseam 46 (FIG. 5) is reduced and the exposed edge 24 of the overseam44 (FIG. 5) is rounded or curved. The action of the solvent iscontrolled to provide a predetermined degree of thickness reductionand/or level of rounding. The solvent should be compatible with theformulation of the dry colorant such that the physical properties andcolor of the article 10 are not significantly affected in a permanentmanner after the coalescence is conclude. The application of the solventis preferably regulated so that the only the margin 18 is wetted. Forsheets 12 formed from thermoplastic resins, suitable solvents include,but not limited to, toluene, methylethyl ketone, methyl isobutyl ketone,and ethanol, capable of providing the desired coalescence.

In another embodiment of the invention, the visual perceptibility of theseam created by the overlapping overseam 44 and underseam 46 of therespective margins 18 (FIG. 5) is reduced or eliminated by providing thearticle 10 (FIG. 5), in at least the vicinity of margin 18, with anadditive or structure that mechanically compresses or collapses upon theapplication of a compressive pressure of a sufficient magnitude as aninitiator after application of article 10 to the surface 28 (FIG. 5).Generally, the magnitude of the compressive pressure, manually-appliedand unaided by mechanical assistance, is less than about 50 pounds persquare inch (PSI) and, typically, is less than about 10 PSI. Thecompressive pressure may be applied using a pressure-applying device,such as a roller, of a suitable width that increases the magnitude ofthe applied compressive pressure due to the mechanical assistance inexcess of the magnitude of the equivalent compressive pressure appliedto the device. It is appreciated that the suitable width may be theentire width of the article 10. The selective collapse of thecollapsible structure reduces the effective thickness of the overlappingoverseam 44 and underseam 46 after a juxtaposed pair of articles 10 isapplied to surface 28.

The compressive pressure may be a differential pressure consisting of afirst pressure applied in the margin 18 and a lesser pressure applied toperipherally inward portions of the article 10. Alternatively, thecompressive pressure may be applied uniformly in those specificembodiments of the invention in which the margin 18 is more susceptibleto the effects of the compressive pressure than the remainder of thearticle 10. In the latter embodiments of the invention, the entirearticle 10 is modified so that the thickness is reduced by theapplication of a compressive pressure and the margin 18 is adapted tohave a greater response to that compressive pressure so that the margin18 experiences a greater thickness reduction than peripherally inwardportions of the article 10. At the point of manufacture, the collapsiblestructure or additive is introduced into the formulation of the drycolorant or into the formulation of the material forming adhesive layer25 (FIG. 5) or, as may be the case, is provided by a suitable formingprocess at the point of manufacture.

In one specific embodiment of the invention and with reference to FIG.10, the article 10 includes a plurality of microparticles 60, usuallygas-filled, that are engineered to collapse or crush upon theapplication of a force at the point of application to surface 28 (FIG.5).

It is appreciated that the gas-filled microparticles 60 may beincorporated in the sheet 12 of dry colorant as shown in FIG. 10, in theadhesive layer 25 as indicated by microparticles 61 shown in phantomlines in FIG. 10, or in both of these components of the article 10. Itis appreciated that the microparticles 60, 61 may be positioned so as tospan the boundary or interface between the adhesive layer 25 and thesheet 12 of dry colorant. The material forming the microparticles 60, 61and the gas filling the interiors of the microparticles 60, 61 should beinert or otherwise non-reactive with the components of the sheet 12and/or adhesive layer 25. Individual gas-filled microparticles 60, 61may be of any closed geometrical shape, such as spheroidal.

The microparticles 60, 61 should have a sufficiently small dimensionsuch that their presence does not introduce outwardly-extendingirregularities perceivable by an observer viewing the front sheetsurface 14 after the article 10 is applied to the surface 28 (FIG. 5)for which a color benefit is desired. Typically, the microparticles 60,61 should have a maximum dimension less than about 75% of the thicknessof the sheet 12 and may have a distribution of particle sizes in which amaximum particle size is less than about 75% of the thickness of thesheet 12. The microparticles 60, 61 may be dispersed uniformlythroughout the volume of the sheet 12 and/or adhesive layer 25 (FIG. 5).Any fragments originating from the collapsed microparticles 60, 61 areretained within the sheet 12 or the adhesive layer 25, as may be thecase.

It is appreciated that, in the alternative, the incorporation ofmicroparticles 60, 61 into the dry colorant of the sheet 12 and/oradhesive layer 25 (FIG. 5) may be limited to the vicinity of margin 18.If the microparticles 60, 61 are present only in the margin 18 (FIG. 5)or in the adhesive layer 25 beneath margin 18, the thickness of theoverlapped overseam 44 and underseam 46 (FIG. 5) will be reduced by theapplication of a compressive pressure thereto. If the microparticles 60,61 are present throughout in the entire sheet 12, a differentialcompressive pressure is applied at the point of application so that theoverlapped overseam 44 and underseam 46 and/or adhesive layer 25 aresubjected to a greater compressive pressure than other portions of thearticle 10. Microspheres in the margin of the article 10 will have areduced survival rate under the action of the differential pressure sothat the overseam 44 and underseam 46 will be thinned collectively morethan the remainder of the sheet 12.

Each of the microparticles 60, 61 has an outer wall 63 formed of anysuitable material that is sufficiently thick and/or mechanically strongto resist crushing or collapse until the application of compressivepressure of a sufficient magnitude at the point of application after thearticle 10 is adhesively secured to the surface 28 (FIG. 5).Microparticles 60, 61 formed of hollow glass spheriods are conventionaland readily apparent to a person of ordinary skill in the art. Exemplarymicroparticles 60, 61 in the form of hollow glass bubbles having adensity in the range of 0.05 g/cc to 0.10 g/cc and a diameter rangingbetween 40 microns and 177 microns are disclosed in U.S. Pat. No.6,194,064 (Keeley et al.). Engineered hollow glass microspheres ofsoda-lime-borosilicate glass composition are available commerciallyunder the tradename SCOTCHLITE® Glass Bubbles from Minnesota Mining &Manufacturing Co. (St. Paul, Minn.).

In an alternative embodiment and with reference to FIG. 11, the article10 may include a plurality of projections 62 extending outwardly fromthe rear sheet surface 16 toward the surface 28 (FIG. 5) when the sheet12 is applied thereto. The projections 62 may be, for example, truncatedconical or frustoconical protrusions that taper from a base near rearsheet surface 16 toward an opposite tip and that have either a circular,oval or polygonal cross-sectional profile when viewed normal to the rearsheet surface 16. It is appreciated that the projections 62 may assumeother geometries capable of collapsing, such as a semi-hemisphericalshape or elongate ridges, without departing from the spirit and scope ofthe present invention. Adjacent ones of the projections 62 are spacedwith a suitable spacing so that the collapse of adjacent ones of theprojections 62 is not interfering. The projections 62 are provided witha tensile strength susceptible to collapse or buckle along an axissubstantially parallel to a surface normal of the surface 28 when acompressive pressure of a sufficient magnitude is applied in a directiongenerally toward the surface 28.

In certain embodiments, the projections 62 may be uniformly distributedacross the rear sheet surface 16 and the projections 62 in the margin 18(FIG. 5) may be configured to be more susceptible to collapse. As aresult, the application of a uniform compressive pressure to the article10 would provide the desired thinning and edge-rounding for overseam 44and underseam 46 (FIG. 5). In other embodiments of the invention, theprojections 62 may have uniform construction and a greater thicknessreduction achieved in the margin 18 by selectively applying adifferential compressive pressure consisting of a larger compressivepressure applied to the overlapping overseam 44 and underseam 46 than inother areas of the article 10. In certain more specific embodiments, theprojections 62 may be provided only in the vicinity of the margin 18 ofthe sheet 12 so that the thickness reduction due to collapsingprojections 62 is limited to the margin 18.

In an alternative embodiment, the adhesive layer 25 (FIG. 5) may beprinted onto the rear sheet surface 16 (FIG. 5) of the sheet 12 with apattern of projections comparable to projections 62, which arecollapsible by a compressive pressure applied at the point ofapplication. Sufficient space is provided between adjacent projectionsof adhesive layer 25 to allow space for the adhesive layer 25 to expandwhen the compressive pressure is applied to precipitate the collapse.

In yet another alternative of the invention and with reference to FIG.12, the sheet 12 or a portion of sheet 12 may be provided with acellular structure including a plurality of cells 64, which may be openand interconnected or isolated and closed. The cells 64 are susceptibleto collapse or buckling when a compressive pressure of a sufficientmagnitude is applied in a direction generally toward the surface 28(FIG. 5). Typically, the cells 64 include contiguous rigid cell walls 65that surround a hollow interior cavity filled with a gas, such as air.Individual cells 64 may be provided with larger dimensions and/or morefragile cell walls 65 in the margin 18 (FIG. 5) than individual cells 64in peripherally inward portions of the sheet 12 and, as a result,collapse to a thinner final structure upon the application of acompressive pressure than peripherally inward portions of sheet 12.Alternatively, the individual cells 64 may have a uniform susceptibilityto collapse and a differential pressure may be employed duringapplication to the surface such that the degree of collapse is greaterin the margin 18 than in the peripherally inward portions of the sheet12. Alternatively, the margin 18 of sheet 12 alone may be provided withthe cellular structure so that only the thickness of the margin 18 issignificantly modified by the application of a compressive pressure. Inyet another alternative and as shown in dot-dashed lines in FIG. 12, theadhesive layer 25 may be provided with a plurality of cells 67,constituting a cellular structure, in addition to, or instead of, thecellular structure of the sheet 12.

In yet another embodiment of the invention and with reference to FIG. 13in which the dimensions are enlarged for purposes of illustration, oneor more of the outer peripheral edges 20, 22, 24 26 of the margin 18 ofsheet 12 are contoured or shaped in a pattern having a plurality ofrepeat elements 66. The repeat elements 66 comprise the individualcomponents of the pattern that collectively provide the contoured edges18, 22. The repeat elements 66 have any configuration, arrangementand/or dimension operative for reducing the visual perceptibility of theoverlapping overseam 44 and underseam 46 (FIG. 5). For monochromatic ornearly-monochromatic colors, the repeat elements 66 and the transitionsbetween adjacent ones of the repeat elements 66 are smoothly curved sothat pointed or jagged portions are absent, although the presentinvention is not so limited. For articles 10 provided with a patternedfront sheet surface 16 (FIG. 5), repeat elements 66 having, or separatedby, jagged edges may be acceptable, according to the principles of theinvention, so as to be complementary to a printed pattern 68 (FIG. 14).

The repeat elements 66 may be either periodic with a constant frequencyand amplitude or aperiodic (i.e., random) with a variable, irregularfrequency and amplitude. Repeat elements 66 having an amplitude and awavelength of about 15 □m to about 12 mm are believed to be acceptable.The repeat elements 66 may be created in sheet 12 during themanufacturing process using any suitable device as would be recognizedby a person of ordinary skill in the art, including but not limited tocutting implements such as pattern shears and laser cutting devices.Alternatively, the repeat elements 66 may be provided at the point ofapplication by, for example, a hand-held tool or applicator device or bya blade or cutter incorporated into an applicator used to apply thearticle 10 to the surface 28 (FIG. 5). The repeat elements 66 alter thelinear nature of the peripheral edge 24 of the overseam 44 (FIG. 5). Theability to perceive the overseam 44 is reduced by the presence of therepeat elements 66 because the human eye tends to perceive an irregularedge less readily than a linear edge.

In yet another embodiment of the invention and referring to FIG. 14, aprinted pattern, indicated generally by reference numeral 68, isprovided on the front sheet surface 14 of the sheet 12. The printedpattern 68 contains various shaded areas or image elements 70 surroundedby contrasting areas 72. The image elements 70 and contrasting areas 72may be configured to provide the printed pattern 68 with a visualperception of depth or may be configured to provide a three dimensionalappearance to an observer. Alternatively, the printed pattern 68 may beprovided with an actual depth or texture in three-dimensions byutilizing certain printing techniques known to persons of ordinary skillin the art. The image elements 70 and contrasting areas 72 maycollectively form any geometrical shape or design effective for reducingthe visual perceptibility of overlapping margins 18. It is contemplatedby the invention that a printed pattern 68 of greater complexity may becreated on the front sheet surface 14 by providing multiple differenttypes of image elements 70 and/or multiple different types ofcontrasting areas 72.

The printed pattern 68 may be generated on the front sheet surface 14 byapplying any ink or dye composition, either solvent-based orwater-based, that is compatible with the dry colorant material formingthe sheet 12. Conventional methods for applying the printed patterninclude gravure, flexography, Mayer rod procedures, slot dieapplicators, roll coaters, and digital printing, each of which isparticularly well-suited useful for applying a printed pattern to sheetmaterial conveyed past a printing station.

Sheets 12 of dry colorant formed from thermoplastic polymer resins maybe provided with a printed image by any suitable printing techniquefamiliar to persons of ordinary skill in the art. Furthermore, theprinted image formed on such sheets 12 may have a relief that provides atextured appearance in addition to a characteristic pattern provided byimage elements 70 and contrasting areas 72.

The image elements 70 of printed pattern 68 may be spaced apart by adistance and with a frequency that reduces the visual perceptibility ofthe overlapping overseam 44 and underseam 46 (FIG. 5). The imageelements 70 constituting the printed pattern 68 typically have anydimension and spacing compatible with seam concealment and configured orarranged so that the printed pattern 68 has no readily perceivedorganization. Adjacent ones of the image elements 70 in the printedpattern 68 may have a periodic, two-dimensional spacing with a lengthyperiodicity so as to not be readily perceived at a normal observationdistance. Preferably, however, the image elements 70 will be any printedpattern 68 of image elements 70 that exhibits no readily perceivedorganization, regularity, directionality, or orientation of theconstituent image elements 70. In such an amorphous or non-orderedpattern, the orientation and arrangement of one image element 70 withregard to a neighboring image element 70 bears no predictable ordiscernable angular or spatial relationship to that of the nextsucceeding image elements 70 beyond. In one specific embodiment of thepresent invention, the printed pattern 68 on the front sheet surface 14may comprise a matrix of pixels, as understood by persons of ordinaryskill in the art. The printed pattern 68 will have a given pixel densitymeasured in dots per inch. Each pixel in the printed pattern 68 ischaracterized by a hue within the visible electromagnetic spectrum and apixel size, typically in the range of about 30 □m to about 100 □m. Theprinted pattern 68 of pixels may be printed on the front sheet surface14 of the sheet 12 with an appropriate printing device, such as a dotmatrix printer, laser printer or an ink jet printer, as understood bypersons of ordinary skill as being operative to apply the ink or dyecomposition onto the surface.

In another embodiment of the invention and with reference to FIG. 15 inwhich feature sizes are exaggerated for illustration, the front sheetsurface 14 (FIG. 2) of the sheet 12 is textured with a three-dimensionaltopography consisting of multiple surface features 74 either relievedinto and projecting outwardly from the sheet 12. More specifically, thesurface features 74 are formed, on a statistical average, above and/orbelow a plane containing the front sheet surface 14 and are spatiallydistributed in either a random fashion or a repeating pattern. Theprofiles of the surface features 74 are of any configuration orcombination of configurations, such as angular, curvilinear, irregular,or the like.

The surface features 74 may be aperiodic or amorphous or may be added asan intentional or a deliberate pattern having a period that exhibits noreadily perceived organization. Preferably, the pattern of surfacefeatures 74 is amorphous in that the surface features are non-uniformwith regard to their size, shape, orientation, and spacing betweenadjacent feature centers. In a completely amorphous pattern, as would bepreferred, the center-to-center spacing of adjacent surface features 74is random, at least within a designer-specified bounded range, such thatthere is an equal probability of the nearest neighbor to a given surfacefeature 74 occurring for any arbitrary angular orientation within theplane of the sheet 12.

One method of creating the surface features 74 is to add a plurality ofparticulates, such as deformable wax prills or granules of anon-compressible material such as sand, to the article 10. Theparticulates may be located in the dry colorant of sheet 12 or in theadhesive layer 25 (FIG. 5) applied to the rear sheet surface 16 of thesheet 12. The spatial distribution of the particulates determines thetopography of the dry colorant, which is preferably aperiodic oramorphous. The particulates have a maximum dimension greater than thethickness of the article 10 and, typically, have a particle size rangeof about 0.15 μm to about 150 μm. After the article 10 is applied to thesurface 28 (FIG. 5), the particulates are visually perceived asoutwardly-projecting irregularities.

Alternatively, the textured pattern of surface features 74 may bestamped, imprinted, embossed or impressed on and/or into the sheet 12using, for example, a stamp or an embossing roller whose relief portionsrepresent the texture as a negative image. The embossing may beaccomplished by the application of sufficient heat and/or sufficientpressure to impart the texture. The textured pattern of surface features74 may be applied at the point of application or at the point ofmanufacture, either before or after the sheets 12 are mounted to thesurface 28 (FIG. 5). The embossing of an amorphous textured pattern inplanar articles during manufacture is described in commonly-owned U.S.Pat. No. 6,193,918 (McGuire, et al.), which is hereby incorporated byreference herein in its entirety. At the point of application, thetextured pattern of surface features 74 may be applied by heat and/orpressure using any suitable hand-held tool, such as an embossing rolleror an applicator for article 10 that incorporates an embossing roller inits construction.

In another embodiment of the present invention, a textured backing layer(not shown) may be associated with the rear sheet surface 16 of thesheet 12 (FIG. 2) either during manufacture or at the point ofapplication. The textured backing layer may be formed of any suitablematerial in which an impressed pattern may be conveyed, such as paperand other cellulosic materials, polymer films and woven or nonwovenfabrics, textile fabrics, glass or ceramic fabrics, and metallizedlayer(s). Alternatively, the backing layer may be one layer of alaminate. The backing layer should exhibit sufficient flexibility toallow bending, rolling and other similar manipulations of the article 10which are required during manufacture and at the point of application.In one specific embodiment, the textured backing sheet is distinct fromthe sheet 12 and is associated with the article 10 at the point ofapplication. To that end, the textured backing sheet is adhesivelysecured to the surface 28 (FIG. 5), and the article 10 is adhesivelybonded to the exposed surface of the textured backing sheet.

In yet another embodiment and with reference to FIGS. 1 and 2, the drycolorant forming the margin 18 is adapted to transmit incidentelectromagnetic radiation having wavelengths in the visible portion ofthe spectrum. The article 10 is applied to surface 28 (FIG. 5) with anoptically opaque margin 18 of one juxtaposed article 10 providing theunderseam 46 (FIG. 5) and the optically transmitting margin 18 of theother juxtaposed article 10 providing the overseam 44 (FIG. 5). In thatcase, the color of margin 18 of the underlying juxtaposed sheet 12 willbe visible through the overlying optically transmitting margin 18 of theother juxtaposed sheet 12. The optically transmitting margin 18 may be atransparent medium having a high optical transmission so that incidentelectromagnetic radiation traverses the margin thickness with littleinterference, such as absorption or reflection. It is appreciated thattotal optical transparency is not required and, to that end, the margin18 of the overlying juxtaposed sheet 12 may be optically translucent sothat the light reflected from the underlying opaque margin 18 isdiffused. It is also contemplated by the invention that the entire sheet12 may be transmissive of radiation having wavelengths in the visibleportion of the electromagnetic spectrum.

In yet another embodiment of the invention, a light diffusing substancemay be added to the formulation of the dry colorant forming sheet 12(FIGS. 1, 2). One specific light diffusing substance is a pearlescentmaterial capable of producing pearlescent-type effects, such as luster,depth, iridescence, metallic sheen, and multiple-color play. Pearlescentmaterials include, but are not limited to, ethylene glycol distearate(EGDS), light diffusing microbeads, mica flakes coated with a metaloxide, pearl essence originating from fish scales or artificiallyproduced, lead carbonate, lead hydrogen arsenate, and bismuthoxychloride. The pearlescent material produces color-effects byinterference, transmission and absorption of light. It is appreciatedthat articles 10 having laminated structures may incorporate that lightdiffusing substance into one or more individual layers. In addition andwith reference to FIGS. 9A and 9B, the light diffusing substance may beprovided only in the margin 18 of one of the visible layer edges of alaminated sheet 12, as shown in FIGS. 9A and 9B.

It is appreciated that the thickness of the dry colorant forming thesheet 12 will affect the perceptibility of the seam formed by theoverlapped overseam 44 and underseam 46. Accordingly, thinning the drycolorant of the entire sheet 12 and the adhesive layer 25 to a thicknessless than about 3 mils may reduce the visual perceptibility of the seam.

The dry color component may exhibit gloss characteristics as desired. Inone embodiment of the invention, the dry color component exhibits glasscharacteristic of conventional architectural paints, such as flat,eggshell, satin, semi-gloss or gloss finishes, as desired. One ofordinary skill in the art will appreciate the difference between suchfinishes and high-gloss finishes such as are employed in, for example,the automotive industry. Gloss may be measured by specular reflectanceof a beam of light at an angle of 60°. Typically, the specularreflectance for the sheet of dry color component of the presentinvention is less than about 60 gloss units at 60°. Specular reflectancemay be measured using the test method described in GM Test SpecificationTM-204-A. The Byk-Mallinckrodt “multi-gloss” or “single gloss” glossmeters can be used for measuring specular gloss of the finished surface.Those gloss meters give values equivalent to those obtained from ASTMMethod D-523-57. Either gloss meter is used with gloss standardscovering the expected range of measurement, together with a piece ofpolished black glass plate of known refractive index. The gloss meter iscalibrated by setting it to read the gloss of a highly polished standardand then reading the gloss of a working standard having a valuepreferably in the range of the test panel. The second standard shouldagree within one unit of its assigned value. At least two readings aretaken on a different area of the test panel. These values are averagedif they agree within one unit. If the range is larger than one unit,additional regions are taken and a mean value is calculated. Desiredgloss characteristics may be obtained by use of particles included inthe dry color component sheet, a topcoat layer, post-treatment,texturization or the like in accordance with techniques known in theart.

It is contemplated by the present invention that the various approachesdescribed herein for eliminating, reducing, or lessening the visualperceptibility of the seam created by the overlap of overseam 44 andunderseam 46 (FIG. 5) may be combined without limitation to provide thedesired seam concealment. As specific examples, the approach ofproviding a printed pattern (FIG. 14) may be used in combination withthinning the dry colorant forming the sheet or the margin (FIGS. 7 and8) and contouring the peripheral edge of the margin (FIG. 13), theapproach of thinning the dry colorant forming the sheet or the margin(FIGS. 7 and 8) may be used in combination with contouring theperipheral edge of the margin (FIG. 13), the approach of thinning thedry colorant forming the sheet or the margin (FIGS. 7 and 8) may be usedin combination with providing a printed pattern (FIG. 14), the approachof thinning the dry colorant forming the sheet or the margin (FIGS. 7and 8) may be used in combination with rounding the peripheral edge ofthe margin (FIGS. 9 and 9A), the approach of thinning the dry colorantforming the sheet or the margin (FIGS. 7 and 8) may be used incombination with adding a light diffusing substance to the dry colorant,the approach of thinning the dry colorant forming the sheet or themargin (FIGS. 7 and 8) may be used in combination with providing atexture with a three-dimensional topography of surface features (FIG.15), the approach of thinning the dry colorant forming the sheet or themargin (FIGS. 7 and 8) may be used in combination with providing acollapsible structure (FIGS. 10 and 11), and the approach of adding arheology-modifying additive, such as a thermally-activated chemicalagent, to the dry colorant may be used in combination with providing atexture with a three-dimensional topography of surface features (FIG.15).

It is also appreciated that the seam collectively formed by theoverlapped overseam 44 and underseam 46 may be an integral part of apattern formed on the surface when the article 10 is applied thereto.For example, the seam may participate in forming a pattern such as ifeach article is shaped as a square or block and multiple blocks areapplied to the surface in a tiled pattern. As another example, thearticle 10 may have a pattern of vertical stripes that accommodate thevertical seam created between juxtaposed articles 10 as a feature in thepattern.

Various methods of forming article 10 are disclosed in U.S. ProvisionalApplication No. 60/343,146, entitled “Articles and Methods for ApplyingColor on Surfaces” and filed on Dec. 20, 2001, U.S. ProvisionalApplication No. 60/380,225, entitled “Articles and Methods for ApplyingColor on Surfaces” and filed on May 13, 2002, and U.S. ProvisionalApplication No. 60/380,205, entitled “Articles and Methods for ApplyingColor on Surfaces” and filed on May 13, 2002, each of which isincorporated by reference herein. Generally, various additives andstructures described herein may be provided to the dry color componentand/or to the adhesive, as may be the case, during the manufacturingprocess producing article 10.

In view of the above, it will be apparent that the articles according tothe present invention may be formed by a variety of methods andtechniques. One such method is disclosed herein for illustrativepurposes only. More particularly, with reference to FIG. 16, a small,laboratory scale, semi-automated process is shown. A releasable liner100 is provided in roll form and is unrolled to travel through assembly102 via rollers 104, 106, 108, 110, 112 and 114 to form a completedarticle 116 which is wound on roll 118. As will be described in furtherdetail below, trimmed portions 120 are directed to roll 122. Thereleasable liner 100 is pulled as a web 101 through the assembly by acombination of the rolls 118 and 122 and a conveyer 124, for example avacuum conveyor. A suitable vacuum conveyor may comprise a continuousconveyor belt with two pulleys having an array of spaced holes that areexposed to the vacuum chamber immediately below. Negative pressure(vacuum) is created by a forced air blower. As the belt passes over thechamber, a negative pressure is created at each hole such that thereleasable liner 100 is securely held to the belt as it passes over thebelt. This effect assists in preventing wrinkles in the releasable liner100 as the applied color component dries. The vacuum conveyor belt speedmay be matched to that of the drive rolls 118 and 122 driven by a drive119. The shaft of a roller 126 from which the releasable liner 100 issupplied is connected with a friction clutch 128 which may be adjustedto obtain sufficient tension in the web 101 for smooth travel throughthe process. A Fife guiding unit 130 may be provided to track the webtravel through the assembly.

A color component, such as wet paint, is applied to the web 101 of thereleasable liner adjacent roller 106 using an applicator 132. The paintor other color component may be water-based or solvent-based as desired.In one embodiment, the applicator 132 comprises a #50 wire wound rodwhich may be held against the roller 106 by spring tension or the likesuch that the web 101 passes between the roller 106 and the applicator132. The color component, such as paint, is introduced at the upstreamside of the wire wound rod applicator 132 by a manifold 134. Themanifold is fed by tubing 136 from a peristaltic pump 138 which drawsthe wet paint from a reservoir 140. To form the sheet of dry colorcomponent, the paint is dried on the web 101, for example as it passesover the vacuum conveyor 124 by the use of dryers. In the embodiment ofFIG. 16, the dryers comprise two infrared heaters 142 which are aided bya forced ambient air duct 144. The air duct 144 may conveniently blowthe exhaust from the vacuum conveyor 124. One skilled in the art willreadily appreciated that solvent or other carrier removed during thedrying process may be captured and recycled as desired. A sheet of drycolor component is thus formed on the releasable liner web.

An adhesive is then applied to the sheet of dry color component on thesurface opposite the releasable liner. For example, in the assembly 102of FIG. 16, adhesive is applied to the surface of the sheet of dry colorcomponent on the web 101 at roller 108 by an applicator 148 which maycomprise, for example, a #20 wire wound rod. The wire wound rodapplicator 148 may be held against the roller 108 by spring tension orthe like such that the web 101 passes between the roller and theapplicator. Liquid adhesive is introduced at the upstream side of thewire wound rod applicator 148 by a manifold 146. The manifold 146 is fedby tubing 150 from a peristaltic pump 152 which draws the liquidadhesive from a reservoir 154. The liquid adhesive in a reservoir 154 iscontinuously stirred by a mixer 156. With the adhesive applied thereon,the web 101 travels to an oscillating fabric covered roller 158 whichtraverses back and forth in the machine direction above a slider plate160 to impart a texture to the liquid adhesive applied to the sheet ofdry color component on the web 101. A textured adhesive may allow thearticle to be more easily repositioned prior to permanent bonding. Theadhesive is then dried, for example, by passing the web 101 under aninfrared heater 162 at roller 110.

In a preferred embodiment, the web 101 travels through rollers 112 and114, one of which is preferably in the form of a rotary cutting knife.In a more specific embodiment, roller 114 comprises two rotary cuttingknives which are arranged adjacent the edges of the web in order to trimthe web edges and provide the final article with the homogenous edges.In another embodiment, the roller 114 comprises a plurality of rotarycutting knife sets which are arranged so as to cut the web into two ormore strips to provide smaller sized articles adapted for applying colorto smaller sized areas as discussed above. The resulting article 116 isthen wound on the roll 118 while the trimmed edges 120 are wound on theroll 122. As set forth above, the described assembly 102 and preparationprocess is illustrative only and variations thereof will be apparent tothose skilled in the art. For example, release agents in the form ofcoatings, layers or the like may be provided in the process.Additionally, the sheet of dry color component may be provided in thefinal article in the absence of a release liner. For example, the sheetof dry color component may be formed on a processing web or forming beltand then separated from the processing web or forming belt prior tostorage in roll or sheet form.

In an alternate embodiment, the articles according to the invention maybe formed using a modified version of the process as described abovewherein two releasable liner webs are employed. For example, a topcoatcomposition for forming a topcoat layer may be applied to a releasableliner web by reverse roll, extrusion coating or the like techniques, anddried thereon, for example with heat. A color component may then beapplied to the dried topcoat layer, for example by reverse roll, gravurecoating, printing, or the like techniques, and dried with heat. Theadhesive may then be applied to a second releasable liner web, followedby laminating the releasable liner-topcoat-dry color component memberwith the adhesive-releasable liner member, with the dry color componentand adhesive in facing relationship. Heat may be provided throughoutthis process by any suitable means including convection or radiation,for example infrared, ultraviolet or the like. One of ordinary skill inthe art will also appreciate that this method may be used to provide anarticle including a single releasable liner by merely removing thesecond releasable liner from the adhesive once the releasableliner-topcoat-dry color component member and the adhesive-releasableliner member have been assembled.

Additional or alternative apparatus and/or processing steps will beapparent to one skilled in the art in view of this description and arewithin the scope of the present invention. For example, the colorcomponent or adhesive could be applied as a single layer or in multiplelayers using a variety of known application techniques includingextrusion, spraying, printing, reverse roll, gravure coating, rollapplication and others known in the art. It is appreciated that theapplication may provide the sheet with a printed pattern. The layers mayhave the same properties or various layers, different from each other,may be employed to combine various properties such as color, strength,opacity, and the like. A blocking agent as described above may beapplied to the adhesive surface and/or may be mixed with the adhesive.Heating may be provided by infrared, convection, or radiation apparatusor other techniques known in the art.

The color component may incorporate additional components, such as alight diffusing substance, particulates, microparticles, or arheology-modifying additive of the invention. Texturization may beprovided on or in one or more layers of the article to provide athree-dimensional topography by incorporating a stamp or an embossingroller into the manufacture processes described herein. In addition, themanufacturing processes described herein may incorporate a cuttingimplement for contouring or shaping at least one of the outer peripheraledges of the sheet of dry color component. The manufacturing process mayalso include a structure for thinning the margins according to theprinciples of the invention.

All documents cited in the Detailed Description of the Invention are, inrelevant part, incorporated herein by reference; the citation of anydocument is not to be construed as an admission that it is prior artwith respect to the present invention.

While particular embodiments of the present invention have beenillustrated and described, it would be obvious to those skilled in theart that various other changes and modifications can be made withoutdeparting from the spirit and scope of the invention. It is thereforeintended to cover in the appended claims all such changes andmodifications that are within the scope of this invention.

1. The combination of an article for applying color on a surface appliedto an architectural surface, comprising: (a) an architectural surface;(b) a first article for applying color on a surface comprising: (i) afirst sheet of dry color component having two surfaces, opposed sideedges, and a side margin along each of said side edges, said first sheetof dry color component comprising an opaque layer of dry paint; and (ii)adhesive on one surface of the first sheet of dry color component,wherein at least said one of said side margins of said first sheet ofdry color component is configured to reduce the visual perceptibility ofa seam created when said first article for applying color on a surfaceis overlapped with a juxtaposed second article for applying color on asurface in that said first sheet of dry color component and saidadhesive have a combined thickness of less than about 3.3 mils, and atleast said one side margin of said first article for applying color on asurface has an opacity index ranging from about 0.95 to 1.0 and aspecular reflectance of less than about 60 gloss units at 60°, and saidfirst article for applying color on a surface is joined by its adhesiveto said architectural surface; and (c) a second article for applyingcolor on a surface: (i) a second sheet of dry color component having twosurfaces, opposed side edges, and a side margin along each of said sideedges, said second sheet of dry color component comprising an opaquelayer of dry paint; and (ii) adhesive on one surface of the second sheetof dry color component, wherein at least said one of said side marginsof said second sheet of dry color component is configured to reduce thevisual perceptibility of a seam created when said second article forapplying color on a surface overlaps said first article for applyingcolor on a surface in that said second sheet of dry color component andsaid adhesive have a combined thickness of less than about 3.3 mils, andat least said margin of said second sheet of article far applying coloron a surface has an opacity index ranging from about 0.95 to 1.0 and aspecular reflectance of less than about 60 gloss units at 60°; whereinsaid second article for applying color on a surface is joined by itsadhesive surface to said architectural surface and to said first articleso that one of the edges of said second article for applying color on asurface overlaps an edge of said first article.
 2. The combination ofclaim 1 wherein: the combination of the first sheet of dry colorcomponent and said adhesive in both side margins of said first articlehave a thickness of less than about 3.3 mils, and both side margins ofsaid first article have an opacity index ranging from about 0.95 to 1.0and a specular reflectance of less than about 60 gloss units at 60°; andthe combination of the second sheet of dry color component and saidadhesive in both side margins of said second article have a thickness ofless than about 3.3 mils, and both side margins of said second articlehave an opacity index ranging from about 0.95 to 1.0 and a specularreflectance of less than about 60 gloss Units at 60°.
 3. The combinationof claim 1 wherein: the entire first article has a first sheet of drycolor component and adhesive with a combined thickness of less thanabout 3.3 mils, an opacity index ranging from about 0.95 to 1.0, and aspecular reflectance of less than about 60 gloss units at 60°; and theentire second article has a second sheet of dry color component andadhesive with a combined thickness of less than about 3.3 mils, anopacity index ranging from about 0.95 to 1.0, and a specular reflectanceof less than about 60 gloss units at 60°.
 4. The combination of claim 1wherein the portion of said first article containing the edge of saidfirst article that is overlapped by the edge of said second articleremains joined to said architectural surface, and the edge of the secondarticle remains overlapped, over the edge of said first article afterthe completion of installation.